Battery Package

ABSTRACT

A battery package is described herein that includes a carton having a sleeve formed from front, rear, and side walls, a closed top, and a closed bottom. The carton defines an interior sized to receive a tray therein. One or more edges of the closed top can be at least partially defined by a line of weakness configured to allow a user to remove the closed top to access the carton interior and the tray therein.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of U.S. application Ser. No. 15/784,018, filed Oct. 13, 2017, which is incorporated herein by reference in its entirety and made a part hereof.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to packages and, more particularly, to packages for batteries.

BACKGROUND

Batteries may start conducting electricity if they come into contact with metal or if the positive terminals of one battery contacts the negative terminal of another battery. As a result, batteries that come into contact with metal or batteries with positive terminals that come into contact with negative terminals will drain quickly and can create heat. Accordingly, proper storage should minimize the occurrence of such events.

SUMMARY

In a first aspect, a battery package is disclosed that includes a tray having a recessed portion and a perimeter flange extending outwardly from edges of the recessed portion about a perimeter of the recessed portion. Curved surface portions are disposed in the recessed portion, where each curved surface portion is configured to receive a cylindrical battery therein. The battery package further includes a carton having a front main wall, a rear main wall, side walls extending between the front and rear main walls, and closed top and bottom portions defining an interior sized to receive the tray therein. One or more edges of the closed top portion are at least partially defined by a line of weakness configured to allow a user to remove the closed top portion to remove the tray from the carton.

In some forms, the battery package can include one or more of the following aspects: a slot opening can extend between the closed top portion and the front main wall and the tray can include a tab that extends upwardly from an edge of the flange thereof and includes a hanging feature, where the tab projects through the slot opening of the carton; the front main wall can include a window extending across a width thereof to provide viewing access to the tray within the carton; the closed top portion can include tabs that are secured together and pivotably coupled to the rear main wall and the sidewalls, respectively; the line of weakness can be at least a portion of the edge between the tab and the rear main wall and, in further forms, the line of weakness can further be at least a portion of the edges between the tabs and the sidewalls; the battery package can include a breakable grip portion formed in one of the sidewalls by a line of weakness that extends adjacent to the closed top portion; the front main wall can project above the closed top portion; the closed bottom portion can include tabs that are secured together and pivotably coupled to the front main wall, rear main wall, and the sidewalls, respectively; or the curved surface portions of the tray can be arranged in a plurality of discrete bays.

In accordance with a second aspect, a blank capable of being formed into a battery package carton is disclosed that includes a central sleeve portion having a front wall, a rear wall, side walls, and a coupling wall pivotably connected together. The front, rear, side, and coupling walls are configured to be folded about one another to secure the coupling wall to one of the front wall, rear wall, or side walls to form a sleeve of the carton. The blank further includes a top portion including tabs pivotably connected to the rear wall and side walls, where the tabs are configured to be secured together to form a closed top of the carton. The closed top further includes a slot gap that extends between the tabs and the front wall. A bottom portion of the blank including tabs that are pivotably connected to the front wall, the rear wall, and the side walls, where the tabs are configured to be secured together to form a closed bottom of the carton, such that the sleeve, closed top, and closed bottom define an interior of the carton.

According to some forms, the blank can include one or more of the following aspects: the front wall can include a window extending across a width thereof to provide viewing access into the interior of the carton after assembly; or one or more edges between the tabs of the top portion can include lines of weakness configured to allow a user to easily tear the corresponding tab off of the carton and, in further forms, one of the sidewalls can include a breakable grip portion formed by a line of weakness that extends adjacent to the edge with the corresponding tab.

In some forms, any of the above blanks can be combined with a tray that is configured to be received within an interior of the carton during formation. The tray can take any of the forms described herein. For example, the tray can include a tab that extends upwardly from an edge of a flange and includes a hanging feature, such that the tab projects through the slot opening of the closed top with the tray received within the carton interior.

In accordance with a third aspect, a method of forming a battery package is disclosed that includes forming a sleeve of a carton by folding a front wall, a rear wall, side walls, and a coupling wall pivotably connected together about one another such that the coupling wall extends along a surface of one of the front wall, rear wall, or side walls and securing the coupling wall to the one of the front wall, rear wall, or side walls. The method further includes forming a closed bottom of the carton by folding tabs pivotably connected to the front wall, the rear wall, and the side walls to positions generally orthogonal to a longitudinal axis of the sleeve and securing the tabs together. The method next includes inserting a tray into the carton and forming a closed top of the carton with the tray received therein by folding tabs pivotably connected to the rear wall and side walls to positions generally orthogonal to the longitudinal axis of the sleeve and securing the tabs together.

According to some forms, the method can further include loading batteries into curved surface portions of a recessed portion of the tray before inserting the tray into the carton.

In accordance with a fourth aspect, a blank capable of being formed into a battery package carton is disclosed that includes a central sleeve portion including a front wall, a rear wall, side walls, and a coupling wall pivotably connected together. The front, rear, side, and coupling walls are configured to be folded about one another to secure the coupling wall to one of the front wall, rear wall, or side walls to thereby form a sleeve of the carton. The blank further includes a top flap pivotably connected to a top edge of the front wall, where the top flap includes a tab, a top wall for the carton, and an outer rear wall pivotably connected together. The blank further includes a bottom flap pivotably connected to a bottom edge of the front wall, where the bottom flap includes a bottom wall for the carton. One of the top flap or bottom flap further includes a coupling tab, such that with the top flap pivoted so that the tab extends along the front wall, the top wall extends over the sleeve, and the outer rear wall extends along the rear wall of the sleeve and the bottom flap pivoted so that the bottom wall extends under the sleeve, the other of the top flap or bottom flap can be secured to the coupling tab to form the carton.

According to some forms, the blank can include one or more of the following aspects: the tab of the top flap and the front wall can be secured together with an adhesive; the tab of the top flap can be configured to extend along a top portion of the front wall projecting upwardly from adjacent portions of the central sleeve portion and, in further forms, a hanging feature can extend through the top portion and the tab of the top flap; the front wall can include a window that extends across a width thereof to provide viewing access into the interior of the carton after assembly; or the blank can be provided in combination with a tray that is configured to be received within an interior of the carton.

In accordance with a fifth aspect, a method of forming a battery package is disclosed that includes forming a sleeve of a carton by folding a front wall, a rear wall, side walls, and a coupling wall pivotably connected together about one another such that the coupling wall extends along a surface of one of the front wall, rear wall, or side walls and securing the coupling wall to the one of the front wall, rear wall, or side walls. The method further includes folding a top flap that is pivotably connected to a top edge of the front wall and includes a tab, a top wall for the carton, and an outer rear wall, such that the tab extends along the front wall, the top wall extends over the sleeve, and the outer rear wall extends along the rear wall of the sleeve. The method further includes folding a bottom flap that is pivotably connected to a bottom edge of the front wall and includes a bottom wall for the carton, such that the bottom wall extends under the sleeve. A coupling tab of one of the top flap or bottom flap can then be secured to a portion of the other of the top flap or bottom flap to form the carton.

According to some forms, the method can further include one or more of the following aspects: the method can include securing the tab of the top flap to the front wall; the method can include forming a hanging feature extending through the tab of the top flap and the front wall; or the method can include inserting a tray into the sleeve before forming the carton

BRIEF DESCRIPTION OF THE DRAWINGS

The above needs are at least partially met through provision of the exemplary battery packages described in the following detailed description, particularly when studied in conjunction with the drawings, wherein:

FIG. 1 is a rear perspective view of a battery package in accordance with various embodiments of the present disclosure;

FIG. 2 is a rear elevation view of the battery package of FIG. 1;

FIG. 3 is a front elevation view of the battery package of FIG. 1;

FIG. 4 is a side elevation view of the battery package of FIG. 1;

FIG. 5 is a top plan view of the battery package of FIG. 1;

FIG. 6 is a bottom plan view of the battery package of FIG. 1;

FIG. 7 is a perspective view of the tray and cover of the battery package of FIG. 1;

FIG. 8 is an exploded perspective view for a second embodiment of a battery package in accordance with various embodiments of the present disclosure;

FIG. 9 is a front elevation view of the battery package of FIG. 8;

FIG. 10 is a side elevation view of the battery package of FIG. 8;

FIG. 11. is a rear elevation view of the battery package of FIG. 8;

FIG. 12 is a top plan view of a first example blank for a carton of a battery package in accordance with various embodiments of the present disclosure;

FIG. 13 is a front perspective view of a carton formed from the blank of FIG. 12;

FIG. 14 is a rear perspective view of a battery package including the carton of FIG. 13;

FIG. 15 is a top plan view of a second example blank for a carton of a battery package in accordance with various embodiments of the present disclosure;

FIG. 16 is a front perspective view of a carton formed from the blank of FIG. 15;

FIG. 17 is a rear perspective view of a battery package including the carton of FIG. 16;

FIG. 18 is a perspective view of an example tray for a battery package in accordance with various embodiments of the present disclosure;

FIG. 19 is a top plan view of a third example blank for a carton of a battery package in accordance with various embodiments of the present disclosure;

FIG. 20 is a front perspective view of a carton formed from the blank of FIG. 19;

FIG. 21 is a rear perspective view of a carton formed by the blank of FIG. 19;

FIG. 22 is a top plan view of a fourth example blank for a carton of a battery package in accordance with various embodiments of the present disclosure;

FIG. 23 is a front perspective view of a carton formed from the blank of FIG. 22;

FIG. 24 is a rear perspective view of a carton formed from the blank of FIG. 22; and

FIG. 25 is a top plan view of a fifth example blank for a carton of a battery package in accordance with various embodiments of the present disclosure.

Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions and/or relative positioning of some of the elements in the figures may be illustrated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful in a commercially feasible embodiment may not be depicted in order to facilitate a less obstructed view of these various embodiments. It will further be appreciated that certain actions and/or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect to sequence is not actually required. It will also be understood that the terms and expressions used herein have the ordinary technical meaning as is accorded to such terms and expressions by persons skilled in the technical field as set forth above except where different specific meanings have otherwise been set forth herein.

DETAILED DESCRIPTION

In one embodiment, a battery package is described herein that advantageously maintains separation between batteries received therein while also providing a resealable opening to sequentially retrieve batteries therefrom. Further, the battery package can include an outer covering or sleeve to hold the various individual components together during storage.

An exemplary battery package 10 of a first form is shown in FIGS. 1-7. The battery package 10 includes a tray 12, a cover 14, and a sleeve 16 that extend generally along a longitudinal axis L. As shown in FIG. 7, the tray 12 is configured to receive batteries 18 having a cylindrical sidewall 20 therein, while the cover 14 is configured to adhere to the tray 12 to secure the batteries 18 therebetween. In a closed configuration, i.e., when the tray 12 is contained within the sleeve 16, the sleeve 16 extends around the tray 12 and cover 14.

Details of the tray 12 are shown in FIG. 7. The tray 12 includes a recessed central portion 22 and a perimeter flange 24 extending outwardly from the recessed central portion 22. The recessed central portion 22 has a back wall 26 and a sidewall 28 that extends between the back wall 26 and the perimeter flange 24. The recessed central portion 22 is configured to receive the batteries 18 therein and, preferably, is sized so that the batteries 18 are fully received therein such that the batteries 18 do not break a plane of the perimeter flange 24.

The back wall 26 includes a plurality of bays 30, each having a surface with a curved, partially cylindrical configuration, each bay 30 extending in a parallel direction along a longitudinal axis L of the package 10. Preferably, the cylindrical configuration of the bays 28 is sized to be complementary to the cylindrical sidewall 20 of the batteries 18 so that when the batteries 18 are received therein, the bays 28 restrict lateral movement thereof. Additionally, a length of the bays 28 between end walls 29 thereof can be sized to be slightly larger, e.g., about 1-5 mm larger than a length of the batteries 18 intended to be received therein. So configured, the bays 28 and the dimensions of the recessed central portion 22 cooperate to restrict movement of the batteries 18. Further, restricting movement of the batteries 18 also advantageously aids in preventing terminals 31 of the batteries 18 from contacting one another when contained within the package 10.

The tray 12 can advantageously be configured to store any desired number of batteries 18 therein. For example, although the illustrated tray 12 includes a row 32 of four bays 30, any desired number of bays 30 can be provided in a row 32. Additionally, as shown in FIG. 7, the tray 12 can include multiple recessed portions 22. The multiple recessed portions 22 can be provided in a stacked configuration with a divider 34 extending therebetween and providing the end walls 29 for the bays 30 on both sides thereof. In one approach, the divider 34 includes a forwardly facing wall 36 extending between the end walls 29. The forwardly facing wall 36 is disposed above a bottom surface of the bays 30 and the end walls 29 can prevent contact between the negative terminal of a battery 18 in a recessed portion 22 and the positive terminal of a different battery 18 in a second recessed portion 22. In the illustrated form, the forwardly facing wall 36 is recessed with respect to the flange 24. Alternatively, the forwardly facing wall 36 can be co-planar with the flange 24.

As shown in FIG. 4, the tray 12 can further include a rearwardly projecting stand portion 38. So configured, the tray 12 can stand in an upright position resting on a bottom edge 40 of the flange 24 along a front 42 thereof and on a bottom edge or surface 44 of the stand portion 38 on a rear 46 thereof. If desired, the flange 24 and stand portion 38 can be sized so that the tray 12 rests at a slightly angled orientation with respect to vertical. For example, the tray 12 can be angled between about 5 degrees and about 30 degrees with respect to vertical, more specifically between about 10 degrees and about 20 degrees, and more specifically between about 10 degrees and about 15 degrees.

In the illustrated form, the stand portion 38 has a generally parallelepiped shape that extends rearwardly from a lower portion 48 of the back wall 26 corresponding to the bottom row 32 of bays 30. With this shape, the stand portion 38 includes a rear wall 50 that is suitable for placement of alphanumeric material (e.g., branding or other identification of the batteries 18), a top wall 54, a bottom wall 56, and side walls 58 extending therebetween. The alphanumeric material can formed in the tray 12 as shown, embossed, printed, adhered thereto using a label, and so forth.

In alternative forms (not shown), the stand portion 38 can be provided by one or more rearwardly extending walls projecting from the back wall 26, the corner between the back wall 26 and sidewall 28, or the bottom edge 40 of the flange 24. The rearwardly extending wall can have any desired configuration, such as generally perpendicular with respect to the longitudinal axis L, at an angle thereto, a plurality of generally vertical walls, and so forth.

The tray 12 can also include a tab 60 having a hanging feature 62, such as a hang hole, projecting therefrom. In the illustrated embodiment the tab 60 is projecting from a top edge 64 of the perimeter flange 24. As shown, while projecting from the perimeter flange 24, the tab 60 is folded towards the back wall 26 to project above an intermediate depth of the tray 12. More specifically, the tab 60 includes a first fold 66 substantially perpendicular to a longitudinal axis L, the first fold 66 extending from the top edge 64 of the flange 24 and a second fold 68 substantially perpendicular to the first fold 66, the second fold 68 being spaced from the first fold 66 by a rearwardly extending wall portion 70, and extending from an edge of the rearwardly extending wall portion 70 opposite from the first fold 66. With this configuration, the tab 60 projects upwardly, generally along the longitudinal axis L when the tray 12 is contained within the sleeve 16. In the illustrated form, the wall portion 70 is sized to be less than a depth of the recessed central portion 22 of the tray 12 and, more specifically, about half the depth of the recessed central portion 22. The hanging feature 62 can take any suitable shape and/or configuration as is commonly understood.

The tray 12 can be made using any suitable method, such as in a mold using pressed paper pulp, injection molding, blow molding, and so forth. Any suitable paperboard or plastic material may be used to make the tray, for example, nylon, polypropylene, polyethylene, polycarbonate, acrylic, polycarbonate, polyvinvyl chloride, and polyethylene terephthalate may be used.

As shown in FIG. 7, the cover 14 has a planar configuration with a footprint generally corresponding to the tray 12 and, more particularly, the flange 24 thereof. In the illustrated form, the cover 14 is a flexible film material. Moreover, the cover 14 can be transparent or translucent so that a user can see the batteries 18 remaining within the tray 12. Of course, the cover 14 can alternatively be a flexible, rigid, or semi-rigid material, as desired. Generally, the cover 14 is manufactured by blown film extrusion, cast film extrusion, and the like. The cover 14 may comprise any suitable paperboard or plastic material, for example, nylon, cellophane, polypropylene, polyethylene, polycarbonate, acrylic, polycarbonate, polyvinvyl chloride, and polyethylene terephthalate may be used. Further, if desired, such as for trays 12 having multiple recessed portions 22, the cover 14 can be divided into multiple, separate portions. For example, each cover 14 can cover one of the recessed portions 22 and adhere to the portion of the flange 24 extending therearound. Additionally, if the divider wall 36 is co-planar with or slightly offset from the flange 24, the cover 14 or covers 14 could additionally adhere to a portion of the divider wall 36 and be perforable such that it can be easily removed once the batteries 18 contained in the row 32 are removed/used.

As discussed above, the tray 12 and cover 14 may be adhesively connected together. In a preferred approach, the tray 12 and cover 14 are coupled together using a resealable adhesive 72 as shown in FIG. 7. For example, the resealable adhesive 72 can be a pressure sensitive adhesive. As such, when a user peels back the cover 14 to remove one or more batteries 18, the user can reseal the cover 14 onto the tray 12 to thereby secure the remaining batteries 18 therein. Moreover, with packages 10 having multiple rows 32 of bays 30, a user need only peel back the cover 14 to expose a desired portion of the tray 12. If desired, a tab 33 of the cover 14 being adhesive-free can be provided so that the user can easily grip the cover 14 for opening. The tab 33 can be in the corner as shown, along a side, or combinations thereof.

By a first approach, the resealable adhesive 72 can be disposed on the perimeter flange 24 of the tray 12. So configured, the cover 14 can be aligned with the flange 24 and applied thereto. With a pressure sensitive adhesive, the cover 14 can be adhered to the flange 24 using pressure.

By a second approach, the resealable adhesive 72 can be disposed on the cover 14 at least in areas corresponding to and capable of contacting the perimeter flange 24 of the tray 12. The resealable adhesive 72 of this form can include a void 74 spaced inwardly from the perimeter of the cover 14 and configured to align with the recessed portion(s) 22 when the cover 14 is adhered to the tray 12. As such, the cover 14 does not adhere to the batteries 18 within the tray 12. The void 74 can be an area without adhesive disposed thereon or can be an area with a deadening material disposed on the adhesive 72 such that the adhesive is rendered inactive.

An example sleeve 16 is shown in FIGS. 1-6. The sleeve 16 includes a front panel 76, a rear panel 78, and side panels 80 extending between the front and rear panels 76, 78. So configured, the sleeve 16 has a tubular configuration extending between a top 82 and bottom 84. As shown, the top 82 and bottom 84 can be open. The sleeve 16 is configured to slide over the tray 12 and cover 14 when they are adhered together.

In the illustrated form, a cross-section of the sleeve 16 has a generally trapezoidal configuration where the front panel 76 has a perimeter corresponding to the perimeter flange 24 of the tray 12 and the cover 14, the rear panel 78 has a width corresponding to a width of the recessed portion 22, and the side panels 80 extend therebetween. The rear panel 78 can have a length that is adapted to abut the stand portion 38 when the tray 12 and cover 14 are fully received within the sleeve 16. As such, the rear panel 78 of this form has a smaller length than the front panel 76. Optionally, the side panels 80 can have a length corresponding to the rear panel 78 as shown or the front panel 76. The sleeve 16 can be made from any suitable material, such as paperboard or cardboard. The sleeve 16 can be cut from a sheet of material and folded as shown in the figures to form the panel portions thereof. In order to hold the tubular form of the sleeve, the sleeve can include overlapping portions, such as along one of the side panels 80 thereof, so that the overlapping portions can be adhered or otherwise secured together. Alternatively, any suitable plastic material, for example, nylon, polypropylene, polyethylene, polycarbonate, acrylic, polycarbonate, polyvinvyl chloride, and polyethylene terephthalate may be used.

As shown in FIG. 1, the sleeve 16 can further include a flap 86 that extends from a top edge 88 of the rear panel 78. The flap 86 is configured to fold over the open top 82 of the sleeve 16 and be secured over the top 82. For example, the flap 86 can be secured to an interior surface of the front panel 76 by any suitable mechanism, such as an adhesive, a mechanical interaction between a tab and an aperture on the flap and a top edge of the front panel 76 and so forth. Alternatively, the flap 86 can secure to flaps extending from a top edge of the side panels 80. If desired, the bottom 84 can include a similar configuration. The flap 86 optionally further includes or defines an elongate slot opening 90. The slot opening 90 can extend through the flap 86 or can be adjacent to an edge thereof. The opening 90 is configured to be disposed in an intermediate position between the front and rear panels 76, 78 when the flap 86 is folded over. As such, when the tray 12 is slid into the sleeve 16, the tab 60 thereof extends through the opening 90 and the wall portion 70 thereof abuts the flap 86. This configuration effectively aligns the tray 12 with the cover 14 adhered thereto within the sleeve 16. Moreover, when the tray 12 is hung on a product display using the hanging feature 62 of the tab 60, the sleeve 16 is prevented from being removed. If desired, the connection between the flap 86 and the rear panel 78 can be a line of weakness, such as a perforation, score line, or the like, so that a user can easily remove the flap 86 after purchase. Similarly, a line of weakness may be included between the tab 60 and the tray 12.

An alternative form for a battery package 100 is shown in FIGS. 8-11. The package 100 of this form includes many similarities to the package 10 described above and as such only the differences will be discussed herein.

The package 100 of this form includes the tray 12′, cover 14′, and sleeve 16′ and further includes a base 102. The base 102 includes a rear wall 104, a sidewall 106, and a perimeter flange 108 extending outwardly from a perimeter of the sidewall 106 opposite the rear wall 104. The base 102 defines an interior 110 configured to receive the tray 12′ therein.

As shown, the tray 12′ nests within the base 102 and is captured between the base 102 and the cover 14′. The resealable adhesive 72′ can be disposed between the cover 14′ and the perimeter flange 108 of the base 102. Alternatively, the cover 14′ can be adhered to the flange 24′ of the tray 12′. As with the above first form, the adhesive 72′ can be disposed on the cover 14′ with the corresponding void 74 or, alternatively, can be disposed on the base perimeter flange 108 and/or the tray flange 24′.

In another aspect, the tab 60′ of the tray 12′ can project upwardly without the folds of the above first form. As such, in one aspect, when the tray 12′ is nested within the base 102, the tab 60′ projects in front of the flange 108 of the base 102 and can be at least partially captured between the flange 108 and the cover 14′ when the cover 14′ is adhered to the base 102. If desired, the sleeve 16′ can optionally include a similarly configured flap 86′ to align the base 102, tray 12′, and cover 14′ within the sleeve 16′. In a second aspect, as with the base 102 shown in FIG. 11, the sidewall 106 can include an elongate opening 111 in a top portion thereof configured to receive the tab 60′ therethrough when the tray 12′ is nested within the base 102.

Moreover, due to the nested configuration of the tray 12′, the base 102 can include a rearwardly projecting portion 112 abutting the rear panel 78′ of the sleeve 16′. Although the rearwardly projecting portion 112 may not be configured to provide a standing feature for the package 100, the portion 112 can have dimensions or configurations similar to the above-described stand portion 38 so that the package 100 can similarly stand in an upright orientation resting on the rearwardly projecting portion 112 and a front edge 114 of the flange 108.

Additional embodiments for battery packages 200 will now be described with reference to FIGS. 12-18. A first form thereof is shown in FIGS. 12-14 having a first width and a second form is shown in FIGS. 15-17 having a second, wider width. It will be understood that the dimensions of the package 200 can be adjusted to accommodate for any desired size and/or number of batteries. For example, the package 200 can be sized to contain various battery sizes including AA, AAA, AAA, D, C, A23, CR123A, CR2, to name a few. Accordingly, although the dimensions are different, the same reference characters will be utilized to refer to the similar structure for each of the forms.

Blanks 202 configured to be formed into cartons 204 for the package 200 are shown in FIGS. 12 and 15. A central sleeve portion 206 of the blank 202 includes a front wall 208, a rear wall 210, side walls 212, and a coupling wall 214 pivotably connected together via longitudinal fold lines/edges 216. In the illustrated form, the central sleeve portion 206 includes, in order, the front wall 208, one of the side walls 212, the rear wall 210, the other of the side walls 212, and the coupling wall 214. For assembly, the walls 208, 210, 212, 214 are pivoted with respect to one another about the fold lines 216 therebetween until the coupling wall 214 extends along a portion of the front wall 208. Thereafter, the coupling wall 214 can be secured to the front wall 208 using a suitable adhesive or other material or mechanism to create a sleeve 218 for the carton 204 as shown in FIGS. 13, 14, 16, and 17. Of course, while the coupling wall 214 is described as being pivotably coupled to one of the side walls 212, the coupling wall 214 can alternatively be pivotably coupled to the front wall 208 or the rear wall 210 and assembly can involve the coupling wall 214 extending along the rear wall 210 or one of the side walls 212.

A bottom portion 220 of the blank 202 includes a front tab 222 connected to the front wall 208, a rear tab 224 connected to the rear wall 210, and side tabs 226 connected to the side walls 212, each pivotably connected to the respective wall 208, 210, 212 via fold lines/edges 228. After the sleeve 218 is formed, the tabs 222, 224, 226 can be pivoted about the fold lines 228 until the tabs 222, 224, 226 overlap portions of one another and extend generally orthogonal to a longitudinal axis L of the sleeve 218. In one approach, the side tabs 226 are folded first, followed by the rear tab 224, and finally overlapped by the front tab 222. During assembly, the overlapping portions of the tabs 222, 224, 226 can be secured together using a suitable adhesive or other material or mechanism so that the bottom portion 220 creates a closed bottom 230 for the carton 204 as shown in FIGS. 13, 14, 16, and 17.

A top portion 232 of the blank 202 includes a rear tab 234 connected to the rear wall 210 and side tabs 236 connected to the side walls 212, each pivotably connected to the respective wall 210, 212 via fold lines/edges 238. After the sleeve 218 is formed, the tabs 234, 236 can be pivoted about the fold lines 238 until the tabs 234, 236 overlap portions of one another and extend generally orthogonal to the longitudinal axis L of the sleeve 218. In one approach, the side tabs 236 are folded first, followed by the rear tab 234. Thereafter, the overlapping portions of the tabs 234, 236 can be secured together using a suitable adhesive or other material or mechanism so that the top portion 232 creates a closed top 240 for the carton 204 as shown in FIGS. 13, 14, 16, and 17. By virtue of the top portion 232 not including a tab extending from the front wall 208, the closed top 240 can include a slot opening or gap 242 (FIG. 13) is disposed between the secured-together tabs 234, 236 and the front wall 208 extending through the closed top 240. Further, if desired, the front wall 208 can be sized with a height greater than the rear and side walls 210, 212 such that the front wall 208 includes a portion 241 that projects above the closed top 240 after assembly of the carton 204.

In the illustrated form, the front, rear, and side walls 208, 210, 212 are generally rectangular. The rear wall 210, however, can have a smaller width than the front wall 208, such that after assembly, the sleeve 218 can have a trapezoidal cross-section in a horizontal plane. Accordingly, the front and rear tabs 222, 224, 234 can have a corresponding trapezoid shape as shown. Further, the side tabs, 226, 236 can extend from their respective fold lines 228, 238 at an angle, such that with the blank 202 laid flat, the side tabs 226, 236 extend above and below the rear wall 210. With this configuration, after the sleeve 218 is assembled, the side tabs 226 project over the open top/bottom of the sleeve 218 to be overlapped by the front and/or rear tabs 222, 224, 234.

Any suitable paperboard or plastic material may be used to make the blank 202, for example, nylon, polypropylene, polyethylene, polycarbonate, acrylic, polycarbonate, polyvinyl chloride, and polyethylene terephthalate may be used. For opaque materials, the front wall 208 can include a window cut-out 243 extending along a width thereof to provide viewing access to an interior 244 of the carton 204 for a consumer to see products stored therein.

The carton 204 can further include an opening feature 246 to provide access to the interior 244 thereof. More specifically, the closed top 240 can include one or more lines of weakness 248, including any combination of perforations, cuts, scores, etc., so that the closed top 240 can be easily fully or partially removed from the carton 204 to thereby provide access to the interior 244. In an alternative or additional form, any of the fold lines described herein can include lines of weakness to facilitate folding the blank 202 to form the carton 204. As shown in the figures, the fold line 238 between the top rear tab 234 and the rear wall 210 can include lines of weakness 248 extending therealong. Further, one or both of the fold lines 238 between the top side tabs 236 and the side walls 212 can include lines of weakness 248 extending therealong. So configured, each of the tabs 234, 236 can be configured to be easily detachable from the corresponding walls 210, 212 of the sleeve 218. If desired, the opening feature 246 can further include a gripping tab 250 defined by a line of weakness 252 in one of the side walls 212 with ends at or adjacent to the fold line 238. So configured, a user can push on the gripping tab 250 to break the gripping tab 250 from the adjacent side wall 212, grip the closed top 240 from above and below, and tear off the closed top 240 to expose an opening to the interior 244. In the illustrated form, the line of weakness 252 provides a domed shape for the gripping tab 250.

The package 200 can further include a tray 254 sized to be received within the carton interior 244. Details of a representation of a suitable tray 254 are shown in FIG. 18. The tray 254 includes a recessed central portion 256 and a perimeter flange 258 extending outwardly from the recessed central portion 256. The recessed central portion 256 has a back wall 260 and a sidewall 262 that extends between the back wall 260 and the perimeter flange 258. The recessed central portion 256 is configured to receive batteries therein and, preferably, is sized so that the batteries are fully received therein such that the batteries do not break a plane of the perimeter flange 258.

The back wall 260 includes a plurality of bays 264, each having a surface with a curved, partially cylindrical configuration, each bay 264 extending in a parallel direction along a longitudinal axis L of the package 200. Preferably, the cylindrical configuration of the bays 264 is sized to be complementary to the cylindrical sidewall of the batteries, as also discussed above, so that when the batteries are received therein, the bays 264 restrict lateral movement thereof. Additionally, a length of the bays 264 between end walls 266 thereof can be sized the same as or sized to be slightly larger, e.g., about 1-5 mm or 1-3 mm, larger than a length of the batteries intended to be received therein. So configured, the bays 264 and the dimensions of the recessed central portion 256 cooperate to restrict movement of the batteries. Further, restricting movement of the batteries also advantageously aids in preventing terminals of the batteries from contacting one another when contained within the package 200.

The tray 254 can advantageously be configured to store any desired number of batteries therein. For example, although the illustrated tray 254 includes two rows 268 of four bays 264, any desired number of bays 264 can be provided in a row 268 and any number of rows 268 can be included. The rows 268 can be disposed in a stacked configuration as shown with a divider 270 extending therebetween and providing the end walls 266 for the bays 264 on both sides thereof. In one approach, the divider 270 includes a forwardly facing wall 272 extending between the end walls 266. The forwardly facing wall 272 is disposed above back wall 260 and the end walls 266 can prevent contact between the negative terminal of batteries in the rows 268. In the illustrated form, the forwardly facing wall 272 is recessed with respect to the flange 258. Alternatively, the forwardly facing wall 272 can be co-planar with the flange 258. In one approach, the flange 258 can have a footprint with a width generally equal to or slightly smaller, e.g., 1-5 mm or 1-3 mm, than a width of the front wall 208 and a height generally equal to or slightly smaller, e.g., 1-5 mm or 1-3 mm, than the rear wall 210 (corresponding to a height of the interior 244). Given the central positioning of the recessed portion 256, the tray 254 is configured to be inserted into the trapezoidal shape of the carton 204.

As shown in FIGS. 14, 17, and 18, the tray 254 can also include a tab 274 having a hanging feature 276, such as a hang hole, projecting therefrom upwardly from a top edge 278 of the perimeter flange 258. The hanging feature 276 can take any suitable shape and/or configuration as is commonly understood. For example, the tab 274 can have a smaller width than the flange 258 and project upwardly from an intermediate portion thereof as shown in FIG. 18. Alternatively, the tab 274 can extend across an entire width of the tray 254 as shown in FIG. 14. With this configuration, when the tray 254 is inserted into the carton interior 244 and the top portion 232 is secured into the closed top 240, the tab 274 can project through the slot opening 242 in the closed top 240. The sidewall 262 of the tray 254 abuts the closed top 240, which prevents the tray 254 from being removed from the carton 204 until the closed top 240 is opened/removed and the hanging feature 276 can be utilized to display the package 200 for sale.

The tray 254 can be made using any suitable method, such as in a mold using pressed paper pulp, injection molding, blow molding, and so forth. Any suitable paperboard or plastic material may be used to make the tray, for example, nylon, polypropylene, polyethylene, polycarbonate, acrylic, polycarbonate, polyvinyl chloride, and polyethylene terephthalate may be used.

Additional embodiments for battery packages 300 will now be described with reference to FIGS. 19-25. A first form thereof is shown in FIGS. 19-21 having a first width, a second form is shown in FIGS. 22-24 having a second, wider width, and a third form is shown in FIG. 25. It will be understood that the dimensions of the package 300 can be adjusted to accommodate for any desired size and/or number of batteries. For example, the package 300 can be sized to contain AA, AAA, AAA, D, C, A23, CR123A, CR2, to name a few. Accordingly, although the dimensions are different, the same reference characters will be utilized to refer to the similar structure for each of the forms.

Blanks 302 configured to be formed into cartons 304 for the package 300 are shown in FIGS. 19, 22, and 25. A central sleeve portion 306 of the blank 302 includes a front wall 308, a rear wall 310, side walls 312, and a coupling wall 314 pivotably connected together via longitudinal fold lines/edges 316. In the illustrated form, the central sleeve portion 306 includes, in order, one of the side walls 312, the front wall 308, the other of the side walls 312, the rear wall 310, and the coupling wall 314. For assembly, the walls 308, 310, 312, 314 are pivoted with respect to one another about the fold lines 316 therebetween until the coupling wall 314 extends along a portion of the front wall 308. Thereafter, the coupling wall 314 can be secured to the front wall 308 using a suitable adhesive or other material or mechanism to create a sleeve 318 for the carton 304 as shown in FIGS. 20, 21, 23, and 24. Of course, while the coupling wall 314 is described as being pivotably coupled to the rear wall 310, the coupling wall 314 can alternatively be pivotably coupled to the front wall 308 or one of the side walls 312 and assembly can involve the coupling wall 314 extending along the rear wall 310 or one of the side walls 312.

As shown in FIGS. 19, 22, and 25, the blanks 302 further include a top flap 320 and a bottom flap 322 that are pivotably connected to upper and lower fold lines/edges 324, 326 of the front wall 308, respectively. The top and bottom flaps 320, 322 are configured to be folded rearwardly so that portions thereof at least partially overlap and the flaps 320, 322 can be secured together. More specifically, the top flap 320 includes a tab 328, which can optionally be divided into two portions 328 a, 328 b, a top wall 330 for the carton 304, and an outer rear wall 332 that extends away from the top wall 330. Each of the portions of the top flap 320 are pivotably connected to each other by fold lines 334. By one approach, the tab 328 can have a shape and dimensions substantially, e.g., within 1-2 mm, equal to a top portion 336 of the front wall 308 that extends upwardly with respect to the adjacent side walls 312. Next, the top wall 330 can have a shape and width/length dimension substantially, e.g., within 1-2 mm, equal to a horizontal cross-section of the sleeve 318. Finally, the outer rear wall 332 can have a shape and dimensions substantially, e.g., within 1-2 mm, equal to the (interior) rear wall 310 of the sleeve 318.

In one form as shown in FIG. 19, the bottom flap 322 includes a bottom wall 338 for the carton 304 pivotably connected to the front wall 308 by the fold line 326 and a coupling tab 340 pivotably connected to the bottom wall 338 by a fold line 342. So configured, after the sleeve 318 is formed the bottom flap 322 can be folded along line 326 so that the bottom wall 338 extends generally orthogonal to a longitudinal axis L of the sleeve 318 across an open bottom thereof, and the coupling tab 340 can be folded along line 342 such that it extends along, e.g., generally parallel with respect to, the rear wall 310 of the sleeve 318. Next, the top flap 320 can be folded along line 324 (FIG. 19) so that the tab 328 extends along, e.g., generally parallel with respect to, the top portion 336 of the front wall 308, along line 334 b so that the top wall 330 extends generally orthogonal to the longitudinal axis L of the sleeve 318 across an open top thereof, and along 334 c so that the outer rear wall 332 extends along the rear wall 310 of the sleeve 318. Finally, the outer rear wall 332 can then be secured to the coupling tab 340 by a suitable adhesive or other material or mechanism to form the final carton 304 securing contents therein. If desired, the tab 328 can be secured to the top portion 336 of the front wall 308 with a suitable adhesive or other material or mechanism.

In another form as shown in FIG. 22, rather than the bottom flap 322, the top flap 320 can include a coupling tab 340′ pivotably coupled to the outer rear wall 332 by a fold line 334 d. So configured, the top flap 320 can be folded along line 324 so that the tab 328 extends along, e.g., generally parallel with respect to, the top portion 336 of the front wall 308, along line 334 b so that the top wall 330 extends generally orthogonal to the longitudinal axis L of the sleeve 318 across an open top thereof, along line 334 c so that the outer rear wall 332 extends along the rear wall 310 of the sleeve 318, and along line 334 d so that the coupling tab 340′ extends along the bottom wall 338. Finally, the coupling tab 340′ can then be secured to the bottom wall 338 by a suitable adhesive or other material or mechanism to form the final carton 304 securing contents therein.

In the illustrated form, the front, rear, and side walls 308, 310, 312 are generally rectangular. The rear wall 310, however, can have a smaller width than the front wall 308, such that after assembly, the sleeve 318 can have a trapezoidal cross-section in a horizontal plane. Accordingly, the top and bottom walls 330, 338 can have a corresponding trapezoid shape as shown. Additionally, in forms of FIGS. 19-24, the blank 302 and resulting carton 304 can include a hanging feature 344, such as a hang hole, that extends through the top portion 336 of the front wall 308 and the tab 328 of the top flap 320. In the illustrated form, a bottom edge of the hanging feature 344 extends along the fold line 334 between the portions 328 a, 328 b of the tab 328. The hanging feature 344 can take any suitable shape and/or configuration as is commonly understood.

Any suitable paperboard or plastic material may be used to make the blank 302, for example, nylon, polypropylene, polyethylene, polycarbonate, acrylic, polycarbonate, polyvinyl chloride, and polyethylene terephthalate may be used. For opaque materials, the front wall 308 can include a window cut-out 346 extending along a width thereof to provide viewing access to an interior 348 of the carton 304 for a consumer to see products stored therein.

In some forms, the cartons 304 can be sized to receive a tray therein, which can be configured as described in the above embodiments. For example, the cartons 304 can be configured to receive a tray configured as shown in FIG. 18 without the tab 274.

Those skilled in the art will recognize that a wide variety of modifications, alterations, and combinations can be made with respect to the above described embodiments without departing from the scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept. 

What is claimed is:
 1. A battery package comprising: a tray having a recessed portion and a perimeter flange extending outwardly from edges of the recessed portion about a perimeter of the recessed portion; curved surface portions disposed in the recessed portion, each curved surface portion configured to receive a cylindrical battery therein; a carton including a front main wall, a rear main wall, side walls extending between the front and rear main walls, and closed top and bottom portions defining an interior sized to receive the tray therein; wherein one or more edges of the closed top portion is at least partially defined by a line of weakness configured to allow a user to remove the closed top portion to remove the tray from the carton.
 2. The battery package of claim 1, wherein a slot opening extends between the closed top portion and the front main wall; and the tray includes a tab extending upwardly from an edge of the flange thereof and including a hanging feature, the tab projecting through the slot opening of the carton.
 3. The battery package of claim 1, wherein the front main wall includes a window extending across a width thereof to provide viewing access to the tray within the carton.
 4. The battery package of claim 1, wherein the closed top portion comprises tabs secured together and pivotably coupled to the rear main wall and the sidewalls, respectively.
 5. The battery package of claim 1, wherein the line of weakness comprises at least a portion of the edge between the tab and the rear main wall.
 6. The battery package of claim 5, wherein the line of weakness further comprises at least a portion of the edges between the tabs and the sidewalls.
 7. The battery package of claim 1, further comprises a breakable grip portion formed in one of the sidewalls by a line of weakness, the breakable grip portion adjacent to the closed top portion.
 8. The battery package of claim 1, wherein the front main wall projects above the closed top portion.
 9. The battery package of claim 1, wherein the closed bottom portion comprises tabs secured together and pivotably coupled to the front main wall, rear main wall, and the sidewalls respectively.
 10. The battery package of claim 1, wherein the curved surface portions of the tray are arranged in a plurality of discrete bays.
 11. A blank capable of being formed into a battery package carton, the blank comprising: a central sleeve portion including a front wall, a rear wall, side walls, and a coupling wall pivotably connected together, wherein the front, rear, side, and coupling walls are configured to be folded about one another to secure the coupling wall to one of the front wall, rear wall, or side walls to form a sleeve of the carton; a top portion including tabs pivotably connected to the rear wall and side walls, the tabs configured to be secured together to form a closed top of the carton, wherein the closed top includes a slot gap extending between the tabs and the front wall; a bottom portion including tabs pivotably connected to the front wall, the rear wall, and the side walls, the tabs configured to be secured together to form a closed bottom of the carton, the sleeve, closed top, and closed bottom defining an interior of the carton.
 12. The blank of claim 11, wherein the front wall includes a window extending across a width thereof to provide viewing access into the interior of the carton after assembly.
 13. The blank of claim 11, wherein one or more edges between the tabs of the top portion comprise lines of weakness configured to allow a user to easily tear the corresponding tab off of the carton.
 14. The blank of claim 13, wherein one of the sidewalls further comprises a breakable grip portion formed by a line of weakness, the breakable grip portion adjacent to the edge with the corresponding tab.
 15. The blank of claim 11 in combination with a tray configured to be received within an interior of the carton, the tray comprising a recessed portion and a perimeter flange extending outwardly from edges of the recessed portion about a perimeter of the recessed portion, wherein the recessed portion includes curved surface portions, each curved surface portion configured to receive a cylindrical battery therein.
 16. The combination of claim 15, wherein the tray includes a tab extending upwardly from an edge of the flange thereof and including a hanging feature, the tab projecting through the slot opening of the closed top with the tray received within the carton interior.
 17. A method of forming a battery package, the method comprising: forming a sleeve of a carton by folding a front wall, a rear wall, side walls, and a coupling wall pivotably connected together, about one another such that the coupling wall extends along a surface of one of the front wall, rear wall, or side walls and securing the coupling wall to the one of the front wall, rear wall, or side walls; forming a closed bottom of the carton by folding tabs pivotably connected to the front wall, the rear wall, and the side walls to positions generally orthogonal to a longitudinal axis of the sleeve and securing the tabs together; inserting a tray into the carton; forming a closed top of the carton with the tray received therein by folding tabs pivotably connected to the rear wall and side walls to positions generally orthogonal to the longitudinal axis of the sleeve and securing the tabs together.
 18. The method of claim 17, wherein the tray comprises a recessed portion and a perimeter flange extending outwardly from edges of the recessed portion about a perimeter of the recessed portion, wherein the recessed portion includes curved surface portions; and further comprising loading batteries into the curved surface portions of the recessed portion before inserting the tray into the carton.
 19. A blank capable of being formed into a battery package carton, the blank comprising: a central sleeve portion including a front wall, a rear wall, side walls, and a coupling wall pivotably connected together, wherein the front, rear, side, and coupling walls are configured to be folded about one another to secure the coupling wall to one of the front wall, rear wall, or side walls to form a sleeve of the carton; a top flap pivotably connected to a top edge of the front wall, the top flap including a tab, a top wall for the carton, and an outer rear wall pivotably connected together; a bottom flap pivotably connected to a bottom edge of the front wall, the bottom flap including a bottom wall for the carton; wherein one of the top flap or bottom flap further includes a coupling tab, such that with the top flap pivoted so that the tab extends along the front wall, the top wall extends over the sleeve, and the outer rear wall extends along the rear wall of the sleeve and the bottom flap pivoted so that the bottom wall extends under the sleeve, the other of the top flap or bottom flap can be secured to the coupling tab to form the carton.
 20. The blank of claim 19, wherein the tab of the top flap and the front wall are secured together with an adhesive.
 21. The blank of claim 19, wherein the tab of the top flap is configured to extend along a top portion of the front wall projecting upwardly from adjacent portions of the central sleeve portion.
 22. The blank of claim 21, further comprising a hanging feature extending through the top portion and the tab of the top flap.
 23. The blank of claim 19, wherein the front wall includes a window extending across a width thereof to provide viewing access into the interior of the carton after assembly.
 24. The blank of claim 19 in combination with a tray configured to be received within an interior of the carton, the tray comprising a recessed portion and a perimeter flange extending outwardly from edges of the recessed portion about a perimeter of the recessed portion, wherein the recessed portion includes curved surface portions, each curved surface portion configured to receive a cylindrical battery therein.
 25. A method of forming a battery package, the method comprising: forming a sleeve of a carton by folding a front wall, a rear wall, side walls, and a coupling wall pivotably connected together about one another such that the coupling wall extends along a surface of one of the front wall, rear wall, or side walls and securing the coupling wall to the one of the front wall, rear wall, or side walls; folding a top flap pivotably connected to a top edge of the front wall and including a tab, a top wall for the carton, and an outer rear wall, such that the tab extends along the front wall, the top wall extends over the sleeve, and the outer rear wall extends along the rear wall of the sleeve; folding a bottom flap pivotably connected to a bottom edge of the front wall and including a bottom wall for the carton, such that the bottom wall extends under the sleeve; and securing a coupling tab of one of the top flap or bottom flap to a portion of the other of the top flap or bottom flap to form the carton.
 26. The method of claim 25, further comprising securing the tab of the top flap to the front wall.
 27. The method of claim 25, further comprising forming a hanging feature extending through the tab of the top flap and the front wall.
 28. The method of claim 25, further comprising inserting a tray into the sleeve before forming the carton. 